Waterax MARK-3 Owner'S Manual Download Page 17

WATERAX

 MARK-3 Owner's Manual 

03/2016 

– Page 17 of 52 

SERVICE 

This section includes instructions for overhaul and maintenance requiring disassembly of 
the 185cc engine and 4-stage pump end model 12-16S. 

Note: It is recommended that all fasteners be replaced with genuine 

WATERAX

 parts. 

Carburetor 

Parts breakdown 

ID

 

ITEM NO

 

DESCRIPTION

 

QTY

 

 

ID

 

ITEM NO

 

DESCRIPTION

 

QTY

 

-  800152 

R-1115 CARBURETOR 

 

22 

800163*†

 

R-1009 DIAPHRAGM "SB" 

600540*†

 

R-1113N GASKET CARBURETOR 

 

23 

301316 

R-1010 DIAPHRAGM COVER 

2  -- 

R-1041 MACHINE SCREW WITH 

LOCK WASHER 

 

24 

800162*†

 

R-1011 FUEL PUMP GASKET 

3  -- 

R-1045 BODY 

 

25 

800164*†

 

R-1012 FUEL PUMP DIAPHRAGM 

4  -- 

R-1040 THROTTLE SHUTTER 

 

26 

301317 

R-1013 ALUMINUM FUEL PUMP BODY 

5  301314 

R-1035 BRASS AND STEEL 
THROTTLE SHAFT AND LEVER 

 

27 

800155†

 

R-1015 FUEL STRAINER SCREEN 

6  301327 

R-1039 STEEL THROTTLE SHAFT 
RETURN SPRING 

 

28 

800159*†

 

R-1016 FUEL STRAINER COVER 
GASKET 

7  301325 

R-1036 THROTTLE SHAFT CLIP 

 

29 

301318 

R-1017 FUEL STRAINER COVER 

8  301326 

R-1037 LOCK WASHER  
1/4 OD X .15 ID 

 

30 

301319 

R-1018 PLATED STEEL MACHINE 
SCREW  

ROUND SLOTTED 

9  -- 

R-1038 MACHINE SCREW 

 

31 

-- 

R-1014 MACHINED SCREW WITH 
LOCK WASHER 

10  800550 

R-1111 BOLT 

 

32 

301266 

R-1025NA INLET CONTROL 
LEVER FULCRUM PIN 

11  -- 

THROTTLE LINK LEVER 

 

33 

800156†

 

R-1029 INLET TENSION SPRING 

12  -- 

R-1110 NUT 

 

34 

800153*†

 

R-1046N INLET NEEDLE, SEAT 

AND GASKET 

13  301315 

R-1005 BRASS CHOKE SHUTTER 

 

35 

301333 

R-1026 INLET CONTROL LEVER 
PINION SCREW 

14  -- 

R-1002 CHOKE FRICTION PIN 

 

36 

800158†

 

R-1022 MIXTURE SCREW O-RING 

15  301334 

R-1003 PLATED STEEL SPRING FOR 
CHOKE FRICTION 

 

37 

301335 

R-1021 SS STEEL FLAT WASHER 
1/4"OD X 3/16"ID 

16  301331 

R-1047 BRONZE INLET SEAT GASKET 

 

38 

301321 

R-1020 STAINLESS STEEL 

MIXTURE SCREW SPRING 

17  301322 

R-1004 CHOKE SHAFT AND LEVER 

 

39 

301324 

R-1019 PLATED STEEL LOW SPEED 

MIXTURE SCREW 

18 

800160*†

 

R-1001 BODY CHANNEL WELCH PLUG 

 

40 

301323 

R-1030 PLATED STEEL HIGH 
SPEED MIXTURE SCREW 

19 

800154†

 

R-1034 NOZZLE CHECK VALVE 

 

41 

-- 

R-1024 IDLE SPEED SCREW SPRING 

20 

800157*†

 

R-1025N INLET CONTROL LEVER 

 

42 

-- 

R-1023 IDLE SPEED SCREW 

21 

800161*†

 

R-1008 DIAPHRAGM GASKET 

 

301330* 

R-1046N-L LONG NEEDLE, SEAT 
AND GASKET 

* Included in R-1050 MARK-3 Carburetor Repair Kit (600178) 

† Included in R

-1049A Carburetor Repair Kit (600162) 

 

Summary of Contents for MARK-3

Page 1: ...MARK 3 Owner s Manual Publication Date 03 2016 Publication Number 701247 Rev 5...

Page 2: ...ubsequent revision WATERAX Inc assumes no responsibility for any omissions or errors that may appear in this document or for any damages that may result from the use of information contained herein Th...

Page 3: ...Cold Weather Operation 12 Removing or Attaching the Pump End 13 Basic Care and Storage 13 Troubleshooting 15 Service 17 Carburetor 17 Troubleshooting 21 Air Filter 22 Fuel Line 22 Fan Cowl Housing 23...

Page 4: ...4 of 52 Pump End Overhaul Procedures 42 Pump Tool Kit 42 Disassembly Procedure for Pump End 12 16S 42 Assembly Procedure for Pump End 12 16S 43 Pump Test 44 Pump Tool Kit 44 Technical Data 45 Pump En...

Page 5: ...r eye and ear protection when operating the pump unit Do not operate if mentally or physically fatigued Always inspect hoses and piping to avoid burst injuries Use only pipe hose and fittings that are...

Page 6: ...causing damage to seals or pump internals It is recommended that all fasteners be replaced with genuine WATERAX parts INTRODUCTION About this Manual This manual contains general operation care and se...

Page 7: ...ry seal Comprehensive manuals The MARK 3 unit has been designed to meet all the requirements of advanced techniques in forest fire control including USDA Forest Service Specifications No 5100 274C Con...

Page 8: ...ess than the recommended portion of oil will cause overheating and possible engine damage Using more than the recommended proportion of oil will cause spark plug fouling erratic carburetion excessive...

Page 9: ...when pumping fuel up to the carburetor gently squeeze the priming bulb Warning Ensure that the fuel tank is positioned away and at a safe distance of the muffler to avoid any potential accident Always...

Page 10: ...rainer to rest on bottom of lake or riverbed Check strainer frequently to make sure that it is not clogged with moss leaves etc DO NOT lift strainer from water while the pump is operating Use a rope o...

Page 11: ...throttle lever to START WARM UP position approximately 3 increments from idle position 4 If equipped with a decompression switch located on the cylinder head push down the valve The valve will close a...

Page 12: ...this position for proper cool down 3 If the pump was last run with foam or water that is salty brackish or high in mineral content flush the pump with fresh water for a minimum of 2 minutes or until...

Page 13: ...ing pins and install 3 Install pump clamp with the lever on the top side tension knob at the bottom Align clamp locating tabs with pump flange locating stub 4 Finger tighten tension knob located at bo...

Page 14: ...setting 10 Check throttle and choke control for proper operation 11 Check fuel line and fittings for signs of wear etc 12 Check starter rope and mechanisms and replace if there are signs of wear 13 M...

Page 15: ...el maximum lift heights will diminish Check that the lift for the elevation the pump is being required to operate at is achievable Pump Does Not Meet Performance Incompatible Suction Hose Verify sucti...

Page 16: ...ean or replace Water or Dirt in Fuel System Drain flush thoroughly Engine Flooded See Flooded engine Improper Timing See Ignition System Engine Backfires Spark Plug Fouled or Defective Clean or replac...

Page 17: ...1018 PLATED STEEL MACHINE SCREW ROUND SLOTTED 1 9 R 1038 MACHINE SCREW 1 31 R 1014 MACHINED SCREW WITH LOCK WASHER 6 10 800550 R 1111 BOLT 1 32 301266 R 1025NA INLET CONTROL LEVER FULCRUM PIN 1 11 TH...

Page 18: ...diaphragm cover plate 6 Remove main diaphragm and main diaphragm gasket 7 Remove inlet control lever fulcrum pin lever and tension spring 8 Remove inlet needle 9 With a thin wall 8 mm 5 16 hex socket...

Page 19: ...to insure complete seal of casting separations of both diaphragms Frequent cleaning or replacement of the fuel strainer screen will aid satisfactory operation of the carburetor To test the carburetor...

Page 20: ...ne fan cooling is reduced If the engine runs too smoothly similar to a 4 cycle engine this indicates that the mixture is too lean Adjust immediately 8 Increase the speed gradually to full throttle set...

Page 21: ...ng screw Clean out orifice by blowing air through high speed adjustment threaded hole Diaphragm Cover Plate Loose Tighten Engine Will Not Idle Incorrect Idle Speed Adjustment Adjust idle speed Dirty N...

Page 22: ...n oiled A tackifier spray can be used on the air filter to help the oil adhere to the air filter Note Apply multi purpose grease on the quadrant teeth when installing the throttle lever sub assembly i...

Page 23: ...SEHEAD ZINC 1 3 800075 CLAMP IGNITION CABLE 1 4 800077 R 411P COWL FAN W STUDS PAINTED 1 5 800047 R 115 STUD M6 X 1 0 X 30 MM LG 3 6 801107 LOCKWASHER M6 SPLIT BOWED ZINC DICHROMATE DIN128A 3 7 800408...

Page 24: ...62 5 COTTER PIN DIN 94 2 5MM X 16MM 3 4 800263 A 4455 CLEVIS PIN FOR LEVER SIDE 2 5 700889 B 4457 PUMP CLAMP BOTTOM HALF 1 6 600110 B 4461 PUMP CLAMP TOP HALF 1 7 800405 A 4454 CLEVIS PIN 1 8 700004 A...

Page 25: ...SPRING REWIND 1 9 800125 R 531 RETAINER SPRING 1 10 800115 R 524 MACH SCREW SHEESE SLOTTED 2 11 800097 R 509 PLUG RUBBER 1 12 800553 R 523 LOCKWASHER M5 SPLIT CADM 2 13 800126 R 532 REWIND STARTER REA...

Page 26: ...ll maintaining pressure on the rope sheave slowly let the rope sheave rotate counterclockwise to allow for the rewind spring 8 to safely unwind 6 Remove rope sheave with the starter rope and starter h...

Page 27: ...ttom 10 Install the pawl assembly Make sure to orientate the pawl assembly as per picture in order for the pawls to function properly 11 Install the friction washer with the serrated teeth facing the...

Page 28: ...ITEM NO DESCRIPTION QTY 600095 C 5200N MOUNTING FRAME WITH HARDWARE 600082 C 5200N 15 HARWARE KIT FOR C 5200N FRAME INCL ALL PARTS EXCEPT C 5201 FRAME 1 600037 A 6149P MARK 3 MOUNTING LEG PLATED 4 2 6...

Page 29: ...g The troubleshooting of the DOS can be done while the MARK 3 is in operation or by using the DTM DOS Testing Module 700773 Below is the normal behavior of the DOS when running on a MARK 3 DOS LED Sta...

Page 30: ...n of spark plug is easily damaged by shock stresses or bending stresses as may be imposed by dropping striking with hard objects or overtightening Therefore if spark plug has been subjected to such ac...

Page 31: ...661 CDI STATOR 800073 Note R 636 Grommet 800074 not shown Stator diagnostics GREEN WIRE FROM COIL GROUND STATOR 225 255 Note The above values are not always a guarantee of perfect efficiency of the pa...

Page 32: ...stator plate 1 1 5 mm counter clockwise and tighten the three screws 3 First pass the green wire through the crankcase hole and then through the grommet Install the grommet on the crankcase 4 Pull the...

Page 33: ...8 701232 R 257NG NIKASIL CYLINDER GREEN GRADE 185CC 1 9 800062 R 117 STUD M8 X 1 25 X 32 MM LG 2 10 800067 R 237 GASKET MUFFLER 1 11 800548 R 119 LOCKWASHER M8 SPLIT ZINC 2 12 800539 R 206 WASHER M8...

Page 34: ...ET CAP ZINC DIN912 3 16 800043 R 130 STUD M10 X 1 5 X 39 MM LG 4 17 800062 R 117 STUD M8 X 1 25 X 32 MM LG 3 5 801107 LOCKWASHER M6 SPLIT BOWED ZINC DICHROMATE DIN128A 5 18 700124 R 136 PUMP MOUNTING...

Page 35: ...00023 R 346 SHIM 020 FLYWHEEL SIDE As req d 800049 R 347 SHIM 039 FLYWHEEL SIDE As req d 800014 R 307 SHIM 008 COUPLING SIDE As req d 800007 R 308 SHIM 012 COUPLING SIDE As req d 800015 R 309 SHIM 016...

Page 36: ...r To determine the cylinder bore use a calibrated dial bore gauge and measure the cylinder bore at a distance of 5 to 10 mm above the exhaust port See image To determine the piston diameter use a cali...

Page 37: ...place with new piston rings 8 Install cylinder with new base gasket 9 Install cylinder head with new cylinder head gasket large band up Tighten nuts uniformly to recommended torque 20 22 Nm 177 195 in...

Page 38: ...re can be switched to 50 1 1 Pre adjust the carburetor see Carburetor adjustments section 2 Start the engine and allow engine to warm up see Carburetor adjustments section 3 Adjust the carburetor see...

Page 39: ...linder and the crankcase studs 6 Remove piston from connecting rod 7 Remove the five machine screws which fasten crankcase halves together 8 To separate crankcase halves on engine with one piece beari...

Page 40: ...rankcase pump side half apply a small amount of 15W40 engine oil on the crankcase seal seat 20 Install the new oil seal R 123 on the coupling side pump side The oil seal must be installed from the ins...

Page 41: ...rings and piston skirt 34 Ensure that the piston rings are correctly positioned piston ring pins should be visible Squeeze the piston rings and slide in the cylinder Ensure that the cylinder is corre...

Page 42: ...2 38 LOCKWASHER 1 4 SPLIT SS 9 11 800359 12 39 SCREW 1 4 28X9 16 SLOT FILLISTER 8 12 700022 A 5537 PROTECTIVE CAP FOR 2 SUCTION 1 13 700029 12 40 BUSHING BEARING BRONZE 1 14 700069 12 13 NOSE FOR SHAF...

Page 43: ...if the internal drive bushing is excessively deformed The drive bushing must be free to rotate without contact with the brass housing If there is contact between the drive bushing and the housing the...

Page 44: ...all remaining protective caps and adaptors Pump Test The best way to verify the condition of your pump unit is to proceed with an actual performance test ID ITEM NO DESCRIPTION QTY 250137 A 2388 PUMP...

Page 45: ...uction cover hub diameter Suction cover bronze bearing bushing bore Suction cover rear face bronze bushing perpendicularity 2 127 2 140 in 0 7495 0 7505 in 0 004 in 54 03 54 36 mm 19 037 19 063 mm 0 1...

Page 46: ...on sleeve cylinder piston ring gap new Cast iron sleeve cylinder piston ring gap wear limit 2 4390 2 4394 in 2 4409 2 4417 in 2 4587 2 4591 in 2 4606 2 4614 in Ra 39 79 in 45 degrees 0 0024 0 0031 in...

Page 47: ...CHARGE 40 600078 A 1887 ALUMINUM GUIDE SHAFT INSTALLATION 40 700024 A 5538 RETAINER FOR PRIMING CAP 40 600079 A 1888 PULLER SUCTION COVER ALU PLATED 40 700029 12 40 BUSHING BEARING BRONZE 40 600081 C...

Page 48: ...ING FRICTION 23 701169 GASKET BURASIL FOR 12 28NS SEAL 41 800088 R 418 SHIELD FAN 21 701170 O RING FOR 12 28NS SEAL 41 800089 R 501 HANDLE FOR STARTER ROPE 23 701232 R 257NG NIKASIL CYLINDER GREEN GRA...

Page 49: ...NNECT 20 800422 C 5200 8 SCREW 1 4 20X1 3 4 HEX CAP SS 20 21 26 801106 R 502N 6 NYLON STARTER ROPE 4 8MM 1400MM 23 800424 C 5200 12 SCREW M10X1 5X30 ZINC 26 801107 LOCKWASHER M6 SPLIT BOWED ZINC DICHR...

Page 50: ...WATERAX MARK 3 Owner s Manual 03 2016 Page 50 of 52 Notes...

Page 51: ...th the Seller s product manuals and supplemental instructions and guidelines as set out in full at www waterax com eng warranty d failure due to compliance with a specification or design provided or r...

Page 52: ...635 Henri Bourassa W Montreal QC H4R 1E1 T 514 637 1818 F 514 637 3985 TF 1 855 616 1818 info waterax com waterax com To help you stay ReadyForWildfires we ve made a few changes placing 100 of our foc...

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